Floor mat and method of making the same



Nov. 17, 1964 MQECKEL 3,156,957

FLOOR MAT AND METHOD OF MAKING THE SAME Filed D60. 1., 1961 Ema-l |2 12|2 I412 11 1| 1| 11 {lo 1111111111111111111111 ll II II II II II II H HII II 1111111111111111111111 11 1111 11 1111111111 1|1|1111111111111111111111 #111111 11111111111111 ll/ll H H II H II H H H HII ,1111 111111L1|1 1|1J11|1 1 3O 32 3 3 :El CE E 24 I I I II H H II HII II (I H II l IO |2 |2 ELIE;- E as 28 ,16 ,28 1o 1% 14 g 14 EIE E /|OC I40 1 28 141 INVENTOR. ROBERT C. MOECKEL BYWMVUMAM ATTORNEYS UnitedStates Patent 3,156,957 FLQOR MAT AND METHOD OF MAKING THE SAME RobertC. Moeelrel, Fort Wayne, Ind, assignor to Late Management, Incorporated,Fort Wayne, End, a corporation of lndiana Filed Dec. 1, 1961, Ser. N156,383 9 Claims. (til. 20--'18'.3)

The present invention relates to a floor mat and method of making thesame, and more particularly to a fioor mat constructed almost entirelyof rubber strips uniquely shaped to be inseparably interlocked together.

Conventional fioor mats fabricated of rubber-like strips of material arebound or held together in a variety of different ways. In one structure,binding wire is used to lock the transverse mat strips together and alsoto bind the edges of the mat. In another construction, the individualrubber-like strips are provided with half-notches shaped complementaryso as to be engageable with each other to thereby form a co-planarstructure in which the crossing strips lie substantially in the sameplane.

These prior art structures have been found to be deficient in a numberof respects. wire bindings and reinforcements, such wires are subject torusting and corrosion which make them unsuitable for a variety of uses,one such use being in a chemical plating factory where acids andchemicals which attack the wire are used. Thus, such mats have a veryshort Wearlife when used in a plating or the like plant.

In other instances, it is desired to have a mat fit a particular sizedfloor or surface, and for this purpose it is necessary to prefabricatethe mat to the exact size needed. The reason for this requirement isthat such mats are normally provided with edge bindings such that afterthe mat has been cut to size it must be provided with such a binding.

In the mats utilizing notches which interfit with each other to providea coplanar structure, it has been found that the crossing strips whichform the mat quite easily become separated either through usage or frombeing laid over irregular surfaces. This, of course, is not desirableinasmuch as it provides a rough surface over which persons may trip andfall or which will become damaged quite early in the wear-life thereofdue to the fact that certain strips are raised higher than others.

In any event, the present invention is intended to overcome certain ofthe prior art difficulties and to provide a mat structure composed ofrubber-like strips wherein the latter are inseparably interlockedtogether and in being so interlocked do not require the use of anyfasteners, bindings or wire reinforcement.

It is therefore an object of this invention to provide a mat formed ofrubber-like strips which extend transversely to each other, these stripsbeing self-interlocking so as not to require the use of any metallicfasteners, bindings, or wire reinforcement.

It is another object of this invention to provide a methed forfabricating the mat of the preceding object in a manner that is facile,economical and eificient.

Other objects will become apparent as the description proceeds.

The above-mentioned and other features and objects of this invention andthe manner of attaining thern'will become more apparent and theinvention itself will be best understood by reference to the followingdescription of an embodiment of the invention taken in conjunction with.the accompanying drawings, wherein:

FIG. 1 is a top plan View of one mat embodiment of this invention;

FIG. 2 is a side view thereof;

In the mats which utilize FIG. 3 is an enlarged fragmentary illustrationtaken substantially along section line 3-3 of FIG. 1;

FIG. 4 is a perspective illustration of the notched strip used in theembodiment of FIGS. 1 and 2;

FIG. 5 is a perspective illustration showing one step in the method offabricating the invention; and

FIG. 6 is another enlarged fragmentary illustration showing another stepin the method of fabricating this invention.

Referring to the drawings, and more particularly to FIGS. 1 and 2, thefloor mat there illustrated includes a plurality of first elongatedstrips 10 and a second plurality of elongated strips 12 which extendtransversely to the strips 19. These strips preferably are formed ofrubber; however, any material of rubber-like constituency having similarelastic properties which permit the material to be stretched willSui-lice for the purposes of this invention.

The strips 10 and 12 are formed differently, as will now be explained.However, both strips 19 and 12 are identical (in the illustratedembodiment) in the respect of being of rectangular cross-section and ofsubstantially the same size.

All of the strips 1%, one such strip being shown in FIG. 3, are providedwith a plurality of longitudinally spaced apertures 14 which preferablyare formed midway between the strip edges 16 and 18 as shown. Theseapertures 14 are preferably square or rectangular in shape with thecorners thereof being rounded or provided with radii for a purpose whichWill become apparent from the following description.

The strips 12, one such strip being shown in FIG. 4, are provided with aplurality of longitudinally spaced pairs of notches 2t] and 22,respectively, which are essentially square or rectangular in shape andwhich extend inwardly toward each other from the opposite edges 24 and26, respectively. The notches 20 and 22 are in transverse alignment, andthey terminate short of each other to define Web portions 28, these webportions being an integral part of each strip 12.

As shown more clearly in FIG. 3, when these .strips 12 are assembled tothe strips 10, the web portions 28 intimately fit into the respectiveapertures 14 with the sides of the notches 2d and 22 engaging theopposite sides of the strip 14 In forming the notches 20 and 22, thewidth dimension thereof is preferably made equal to the thicknessdimension of the strip 10 such that when the strips 10 and 12 arefastened together, the sides of the notches 2d and 22 will intimatelyengage the opposite sides 343 and 32 of the strip it As shown moreclearly in FIG. 1, the finished mat has all of the strips lil arrangedin spaced-apart parallel relation with all of the apertures 14 beingtransversely aligned. Thus, all of the strips 12 which are fitted intothe apertures ll l extend in directions which are at right angles to thestrips It In fabricating the mat of FIGS. 1 and 2, the followdngdescribed procedure is followed. It will have been recognized up to thispoint that the cross-sectional size of each aperture 14 is substantiallysmaller than the crosssectional area of each strip 12. This being true,it is not possible to insert the strips 12 into the apertures 14 unlessthe latter can be enlarged or the strips 12 made smaller. In FIGS. 5 and6 is illustrated one method by which the strip 12 may be insertedthrough the aperture 14. As the first step in the procedure, the strip10 is stretched in a longitudinal direction so as to elongate theaperture 14 to a form as indicated by the reference numeral 14a. Whenthis is done, the strip 12 is inserted through the elongated aperturelea until the notches 2i) and 22 as well as the web portion 28 becomeregistered therewith. With the strip 12 in this position, it is rotatedto the position shown in FIG. 6. While the strip 12 is in this position,the stretching force exerted on the strip It) is released, therebypermitting the aperture 14a to reduce to the size of the aperture 14 inwhich the web portion 28 is intimately gripped or surrounded. Theaperture 14 preferably is of the same size as the cross-section of webportion 28. Thus assembled, the strips and 12 become firmly interlockedtogether and cannot be separated without destroying the mat unless theprocedure of assembling is followed in reverse.

While the invention has been shown in connection with the strips 10 and12 being orthogonally related, it will at once be apparent to the personskilled in the art that almost any geometric pattern for the strips maybe used. For example, the strips 10 may be arranged as concentriccircles and the strips 12 as radii of the circles. Also, triangularpatterns may be used wherein the strips 1% and 12 cross at angles otherthan 90.

It will at once become apparent that mats may be fabricated to almostany size and then cut to fit the outline of a fioor surface on which itis to be laid. This mat requires no fasteners, bindings or wirereinforcement of any type; hence, the mat may be used in any environmentin which rubber or rubber-like material is not attached but wire ormetallic parts are attached. Mats rnade according to this invention arequite versatile as to the end usagesthereof, and these will appear asobvious to a person skilled in the art.

In a preferred mat design, the edges 16 and 24 of the strips 10 and 12,respectively, lie in a common plane as do the edges 18 and 26. While thenotches 2t and 22 have been specified as being square or rectangular inshape, they may be of some different shape which may either intimatelyengage or not engage at all the sides 30 and 32 as may be desired in thefinal design.

An alternative method in the assembly of the mat is to stretch intoelongated form the notched strips 12 instead'of the apertured strips 10.In doing so, the strips 12 are stretched suificiently to reduce thecross-sectional size thread thereof to a size smaller than the apertures14 in which condition the stretched strip 12 is merely threaded throughthe respective apertures 14 until the notch pairs 29, 22 come intoregistry therewith. The stretching is thereupon released permitting thenotches and 22 to straddle the respective strips 1%. Of course,

the strip 12 will have to be rotated ninety degrees to the positionshown in FIG. 6 either before-or after the stretching has been released.

While I have described above the principles of my invention inconnection with specific apparatus, it is to be clearly understood thatthis description is made only by way of example and not as a limitationto the scope of my invention.

What is claimed is:

l. The method of fabricating a mat of first and second rubber-likestrips of the same cross-sectional size and shape, said strips beingrectangular in cross-section and having opposite sides and edges,comprising the steps of forming a plurality of longitudinally spacedapertures through the sides of said first strips, arranging said stripssuch that said apertures, respectively, are transversely aligned,stretching said first strips longitudinally to elongate said aperturesto a size that will pass said second strips respectively ltherethrough,forming a plurality of longitudinally spaced pairs of notches in saidsecond strips, said notches extending inwardly toward each other fromopposite edges of said second strips and terminating short of each otherthereby defining web portions therebetween, said web portions having across-sectional size substantially equal to said apertures inunstretched form, inserting said second strips through the alignedelongated apertures respectively to a point at which said web portionsbecome registered with said apertures, rotating Cir 4 releasing thestretching of said first strips whereby said apertures collapse ontosaid Web portions and said notches straddle said first strips.

2. The method of fabricating a mat comprising the steps of forming aplurality of longitudinally spaced apertures in a first plurality ofelongated rubber-like strips, forming a plurality of longitudinallyspaced notches in a second plurality of elongated strips, said notchesextending transversely of said second strips from one side thereof andterminating short of the opposite side to thereby define Web portions,said web portions having a crosssectional size substantially equal .tosaid apertures, stretching the strips of one of said first and secondpluralities until said second strips will pass through said apertures insaid first strips, respectively, inserting said second strips throughthe apertures of said first strips to a point at whi h said web portionsbecome registered with said apertures, and releasing said stretchinguntil said notches straddle said first strips and said Web portionssubstantially fill said apertures, respectively.

3. A mat comprising a first plurality of elongated rubber strips, saidstrips being rectangular in cross-section and having opposite parallelsides, said strips being spaced apart and parallel with all of the sidesthereof also being parallel, each strip having a plurality of spacedapart rectangular apertures therein, material of each strip whichimmediately surrounds said apertures being solid and uninterrupted, theapertures of all said strips being transsaid second strips in saidapertures until the sides thereof versely aligned, respectively, asecond plurality of elongated rubber strips which are rectangular incross-section to thereby be provided with opposite sides and edgesrespectively, said second strips having a plurality of longitudinallyspaced notch pairs therein, each notch pair comprising two transverselyaligned rectangular notches which extend inwardly toward each other fromthe opposite edges of the respective second strip butwhich terminateshort of each other to provide a Web portion of said second striptherebetween, said first and second strips being interlocked together intransverse relationship with said web portions intimately fitting intorespective apertures of said first strips and tightly engaging all sidesthereof and with said notches straddling and intimately engaging theopposite sides of said first strips respectively, said first and secondstrips having the same cross-sectional dimensions between said aperturesand notches, respectively.

4. A mat comprising a first plurality of elongated rubber strips whichare rectangular in cross-section and which have opposite sides and edgesrespectively, said strips being spaced apart and parallel with all ofthe sides thereof also being parallel, each strip having through thesides thereof and intermediate the edges a plurality of spaced apart,rectangular apertures, the apertures of all of said strips beingtransversely aligned, respectively, the material ofeach strip whichimmediately surrounds said apertures being solid and uninterrupted, asecond plurality of elongated rubber strips which are rectangular incross-section and which have opposite sides and edges respectively, saidsecond strips each having a plurality of longitudinally spaced pairs ofnotches therein, each pair of notches being in transverse align ment andextending inwardly toward each other from the respective edges of saidsecond strip, each pair of notches terminating short of each other todefine a web portion therebetween, said first and second strip beinginterlocked together, said first strips being transverse to said secondstrips, said second strip being spaced apart and parallelwith the sidesthereof also being parallel, the sides of said first and second stripslying in planes respectively which intersect each other in straightlines which are normal to said edges, said web portions fitting into andtightly engaging all sides of said apertures, re-, spectively, and saidnotches straddling the sides respectively of said first strips.

5. A mat comprising a first plurality of elongated rubber strips whichare rectangular in cross-section and whlch have opposite sides and edgesrespectively, said strips being spaced apart and parallel with all ofthe sides thereof also being parallel, each strip having through thesides thereof and intermediate the edges a plurality of spaced apartapertures having sides at right angles to each other, the apertures ofall said strips being transversely aligned, respectively, the materialof said strips immediately surrounding said apertures being solid anduninterrupted, a second plurality of elongated rubber strips which arerectangular in cross-section and which have opposite sides and edgesrespectively, said second strips each having a plurality oflongitudinally spaced pairs of notches therein, each pair of notchesbeing in transverse alignment and extending inwardly toward each otherfrom the respective edges of said second strip, each pair of notchesterminating short of each other to define a web portion therebetween,said first and second strips being interlocked together, said firststrips being transverse to said second strips, said second strips beingspaced apart and parallel with the sides thereof also being parallel,said web portions fitting into said apertures and tightly engaging allsides thereof, respectively, said notches straddling the sidesrespectively of said first strips, and each of said web portions havinga cross-sectional size and shape which is substantially identical to thesizes and shape of the respective aperture.

6. A mat comprising a first plurality of elongated rubber strips whichare rectangular in cross-section and which have opposite sides and edgesrespectively, said strips being spaced apart and parallel with all ofthe sides thereof also being parallel, each strip having through thesides thereof and intermediate the edges a plurality of spaced apart,rectangular apertures, the apertures of all said strips beingtransversely aligned respectively, the material of said stripsimmediately surrounding said apertures being solid and uninterrupted, asecond plurality of elongated rubber strips which are rectangular incrosssection and which have opposite sides and edges respectively, saidsecond strips each having a plurality of longitudinally spaced notchestherein, each notch extending inwardly from the respective edge of saidsecond strip but terminating short of the opposite edge to define a webportion, said first and second strips being interlocked together, saidfirst strips being transverse to said second strips, said second stripsbeing spaced apart and parallel with the sides thereof and also beingparallel, the sides of said first and second strips lying in planesrespectively which intersect each other in straight lines which arenormal to said edges, said web portions intimately fitting into saidapertures and tightly engaging all sides thereof, respectively, and saidnotches straddling the sides respectively of said first strips.

7. A mat comprising a first plurality of elongated rubber-like strips,said strips being spaced apart and having a plurality of longitudinallyspaced apertures therethrough, the apertures of said strips beingaligned in a direction transverse thereto, the material of said stripswhich immediately surrounds said apertures being solid anduninterrupted, a second plurality of elongated rubher-like strips eachhaving a plurality of longitudinally spaced pairs of notches therein,each pair of notches being in transverse alignment and extendinginwardly toward each other from the respective opposite sides of saidsecond strip, each pair of notches terminating short of each other todefine a web portion therebetween, said first and second strips beinginterlocked together, said first strips extending transversely to saidsecond strips, said Web portions fitting into and tightly engaging allsides of said apertures, respectively, and said notches straddling saidfirst strips thereby locking said first and second strips together.

8. The method of fabricating a mat of first and second rubber-likestrips of the same cross-sectional size and shape, said strips beingrectangular in cross-section and having opposite sides and edges,comprising the steps of forming a plurality of longitudinally spacedapertures through the sides of said first strips leaving the materialwhich immediately surrounds said apertures solid and uninterrupted,arranging said first strips such that said apertures, respectively, aretransversely aligned, stretching said first stri s longitudinally toelongate said apertures to a size that will pass said second stripsrespectively therethrough, forming a plurality of longitudinally spacedpairs of notches in said second strips, said notches extending inwardlytoward each other from opposite edges of said second strips andterminating short of each other thereby defining web portionstherebetween, said web portions having a cross-sectional sizesubstantially equal to the size of said apertures in unstretched form,inserting said second strips through the aligned elongated aperturesrespectively to a point at which such web portions become registeredwith said apertures, rotating said second strips in said apertures untilthe sides thereof intersect said edges in lines normal to the latter,and then releasing the stretching of said first strips whereby saidapertures collapse onto said web portions and tightly engage all sidesthereof and said notches straddle said first strips.

9. The method of fabricating a mat comprising the steps of forming aplurality of longitudinally spaced apertures in a first plurality ofelongated rubber-like strips leaving the material which immediatelysurrounds said apertures solid and uninterrupted, forming a plurality oflongitudinally spaced notches in a second plurality of elongated strips,said notches extending transversely of said second strips from one sidethereof and terminating short of the opposite side to thereby define webportions, said web portions having a cross-sectional size substantiallyequal to the size of said apertures, stretching the strips of one ofsaid first and second pluralities until said second strips will passthrough said apertures in said first strips, respectively, insertingsaid second strips through the apertures of said first strips to a pointat which said web portions become registered with said apertures, andreleasing said stretching until said notches straddle said first stripsand said web portions substantially fill said apertures and tightlyengage all sides thereof, respectively.

References Cited in the file of this patent FOREIGN PATENTS 458,804Great Britain 1936

3. A MAT COMPRISING A FIRST PLURALITY OF ELONGATED RUBBER STRIPS, SAIDSTRIPS BEING RECTANGULAR IN CROSS-SECTION AND HAVING A OPPOSITE PARALLELSIDES, SAID STRIPS BEING SPACE APART AND PARALLEL WITH ALL OF THE SIDESTHEREOF ALSO BEING PARALLEL, EACH STRIP HAVING A PLURALITY OF SPACEDAPART RECTANGULAR APERTURES THEREIN, MATERIAL OF EACH STRIP WHICHIMMEDIATELY SURROUNDS SAID APERTURES BEING SOLID AND UNINTERRUPTED, THEAPERTURES OF ALL SAID STRIPS BEING TRANSVERSELY ALIGNED, RESPECTIVELY, ASECOND PLURALITY OF ELONGATED RUBBER STRIPS WHICH ARE RECTANGULAR INCROSS-SECTION TO THEREBY BE PROVIDED WITH OPPOSITE SIDES AND EDGESRESPECTIVELY, SAID SECOND STRIPS HAVING A PLURALITY OF LONGITUDINALLYSPACED NOTCH PAIRS THEREIN, EACH NOTCH PAIR COMPRISING TWO TRANSVERSELYALIGNED RECTANGULAR NOTCHES